37th FVI Expert Breakfast

Topic: "TPM does not fail because of the method, but because of the consistency" – A practical report from Gira.

In this session, Timo Gumprecht (Gira) showed how to turn TPM (Total Productive Maintenance) from a theoretical concept ("buzzword") into a lived culture.

• The "Most Expensive Silo": Timo quoted Tilo Brinkmann: The most expensive silo is the mindset "I am waiting for maintenance". TPM breaks this down by transferring responsibility to the operator ("Autonomous Maintenance").
• From Chaos to Structure: Before TPM, Gira's maintenance worked "with the phone in the pocket" and Excel shift books. Today, there are standardized maintenance plans, shadow boards, and QR codes on every system.
• QR Codes for Everyone: Gira has attached QR codes to machines that lead directly to cleaning instructions (Microsoft Forms). It's so simple that any operator can use it. Result: Operators proactively report leaks before the system stops.
• The 3-Class Society: Timo admitted that it's not perfect yet. For complex systems, TPM works great, but for simple systems, the maintainer still has to ask: "Have you cleaned today?". It's a process, not a switch.
• Management Support is Everything: Peter Vogtmann (participant) emphasized: "Without management support, you have no funds and run yourself into the ground." You have to give management "treats" (e.g., reduced costs, longer machine lifespan) to justify the budget for TPM.

Classification: TPM needs digital tools

This episode is a perfect example of "Smart TPM" with ADAM.

• Autonomous Maintenance with ADAM: Timo uses Microsoft Forms for cleaning plans. ADAM makes it more professional. The operator scans the QR code and sees the checklist directly in the app. If he finds a defect (e.g., 'motor leaking'), he can immediately take a photo and create a ticket for maintenance. This closes the feedback loop.
• Knowledge Transfer: Timo mentioned that operators need to be trained ("Train the Trainer"). ADAM is the digital trainer. If the operator doesn't know how to change the filter, ADAM shows him a short video or a step-by-step guide. This enables 'training on the job' without always needing a supervisor present.
• Measurability: Jens Reisenweber demanded that TPM successes must be measurable (for management). ADAM provides the data. You see at the push of a button: How many defects were found by operators? How has the OEE developed? These are the 'treats' you can show your boss.

Conclusion: TPM is culture, but software (ADAM) makes the culture scalable. Instead of Excel lists and notes, there is a digital standard that empowers every employee.